ARMY TM 9-2320-365-34-1 AIR FORCE T.O. 36A12-1B-1095-12-1ARMY TM 9-2320-365-34-1 AIR FORCE T.O. 36A12-1B-1095-12-1 TECHNICAL MANUAL HEADQUARTERS NO. 9-2320-365-34-1 DEPARTMENTS OF

ARMY TM 9-2320-365-34-1AIR FORCE T.O. 36A12-1B-1095-12-1

TECHNICAL MANUALMAINTENANCE INSTRUCTIONS

DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCEM1078 SERIES, 2 1/2-TON, 4 X 4,

LIGHT MEDIUM TACTICAL VEHICLES (LMTV)

VOLUME NO. 1 OF 2HOW TO USE THIS MANUALPAGE vii

GENERAL INFORMATIONPAGE 1-1

VEHICLE MAINTENANCEPAGE 2-1

MODEL NSN EIC VEHICLE TROUBLESHOOTINGPAGE 2-8TRK, CAR., LMTV, M1078

W/WN 2320-01-360-1898 BHHW/O WN 2320-01-354-3385 BHD

TRK, VAN, LMTV, M1079W/WN 2320-01-360-1891 BHGW/O WN 2320-01-354-3384 BHE

TRK, CHAS, LMTV, M1080W/O WN 2320-01-353-9098 BHC

TRK, CAR., LMTV, AIR DROP, M1081W/WN 2320-01-360-1899 BHJW/O WN 2320-01-355-3064 BHF

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENTS OF THE ARMY AND THE AIR FORCE

17 JUNE 1998

ARMY TM 9-2320-365-34-1AIR FORCE T.O. 36A12-1B-1095-12-1

TECHNICAL MANUAL HEADQUARTERSNO. 9-2320-365-34-1 DEPARTMENTS OF THE ARMY

AND THE AIR FORCETECHNICAL ORDERNO. 36A12-1B-1095-12-1 Washington, D.C., 17 June 1998

Direct Support and General Support Maintenance ManualM1078 SERIES, 2 1/2-TON, 4 x 4,

LIGHT MEDIUM TACTICAL VEHICLES (LMTV)

VOLUME NO. 1 OF 2

MODEL NSN EIC

TRK, CAR., LMTV, M1078W/WN 2320-01-360-1898 BHHW/O WN 2320-01-354-3385 BHD

TRK, VAN, LMTV, M1079W/WN 2320-01-360-1891 BHGW/O WN 2320-01-354-3384 BHE

TRK, CHAS, LMTV, M1080W/O WN 2320-01-353-9098 BHC

TRK, CAR., LMTV, AIR DROP, M1081W/WN 2320-01-360-1899 BHJW/O WN 2320-01-355-3064 BHF

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve theprocedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment TechnicalPublications), through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet addressis http://aeps.ria.army.mil. If you need a password, scroll down and click on "ACCESS REQUEST FORM". TheDA Form 2028 is located in the ONLINE FORMS PROCESSING section of the AEPS. Fill out the form and clickon SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and bettermanage the DA Form 2028 program. You may also mail, fax or Email your letter or DA Form 2028 direct to:AMSTA-LC-CI/TECH PUBS, TACOM-RI, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The email addressis [email protected]. The fax number is DSN 793-0726 or Commercial (309) 782-0726.

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

TABLE OF CONTENTSPage

HOW TO USE THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Section I General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1Section II Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Section III Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

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CHAPTER 2 VEHICLE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Section I Repair Parts, Special Tools and Test, Measurement and Diagnostic Equipment . . 2-1Section II Service Upon Receipt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Section III Troubleshooting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Section IV Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-983

CHAPTER 3 ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

CHAPTER 4 FUEL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1


CHAPTER 5 COOLING SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

CHAPTER 6 ELECTRICAL SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

CHAPTER 7 TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1


CHAPTER 8 POWER TRANSFER AND FINAL DRIVE ASSEMBLY MAINTENANCE . . . . . 8-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

CHAPTER 9 FRONT AXLE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1


CHAPTER 10 REAR AXLE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

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PageCHAPTER 11 BRAKE SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1


CHAPTER 12 STEERING SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2

CHAPTER 13 FRAME MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1


CHAPTER 14 SUSPENSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-2

CHAPTER 15 BODY AND CAB MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15-2

CHAPTER 16 11K SELF-RECOVERY WINCH (SRW) MAINTENANCE . . . . . . . . . . . . . . . . . 16-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-2

CHAPTER 17 HYDRAULIC SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-2

CHAPTER 18 KIT MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-2

CHAPTER 19 ARMAMENT/SIGHTING AND FIRE CONTROL MATERIAL MAINTENANCE 19-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-2

CHAPTER 20 ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1


CHAPTER 21 TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1


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TABLE OF CONTENTS (CONT)Page

CHAPTER 22 POWER TRANSFER AND DRIVE ASSEMBLY MAINTENANCE . . . . . . . . . . . . 22-1


CHAPTER 23 FRONT AXLE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-2

CHAPTER 24 REAR AXLE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1Section I Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1Section II Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-2

APPENDIXESA. REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1B. TOOLS AND SPECIAL TOOLS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1C. EXPENDABLE AND DURABLE ITEMS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1D. ILLUSTRATED LIST OF MANUFACTURED ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1E. TORQUE LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1F. MANDATORY REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1G. ADDITIONAL AUTHORIZATION LIST (AAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1H. TRANSMISSION/TRANSMISSION CONTROLS ADAPTABILITY CHART . . . . . . . . . . . . . . . . . . . H-1

SUBJECT INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary-1

LIST OF ILLUSTRATIONS

Figure Title Page1-1 M1078 Truck, Cargo: 2 1/2-Ton, 4x4, Dropside . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21-2 M1079 Truck, Van: 2 1/2-Ton, 4x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31-3 M1080 Truck, Chassis: 2 1/2-Ton, 4x4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41-4 M1081 Truck, Cargo: 2 1/2-Ton, 4x4, Air Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-51-5 Powertrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-6 Engine Air Intake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91-7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101-8 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121-9 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-141-10 Engine Starting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-151-11 Service Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-161-12 Blackout Lighting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-171-13 Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-181-14 Troubleshooting Aid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-191-15 Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-201-16 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-221-17 11K Self-Recovery Winch (SRW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-231-18 Air Transportability Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-241-19 Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26D-1 Brake Adjusting Tool Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-5D-2 Brake Plunger Seal Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-6D-3 Cab Front Support Spanner Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7D-4 Cab Maintenance Stand Angle Brackets and Straight Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9

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LIST OF ILLUSTRATIONS (CONT)

Figure Title Page

D-5 Cab Maintenance Stand Base Angle Bracket Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10D-6 Cab Maintenance Stand Base Fabrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-11D-7 Cab Maintenance Stand Brace Bracket Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-12D-8 Cab Maintenance Stand Brace to Base Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-13D-9 Cab Maintenance Stand Side Braces Side View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-14D-10 Cab Maintenance Stand Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-15D-11 Cab Support Tool Strut and Cab Rest . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-16D-12 Cab Support Tool Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-17D-13 Cab Support Tool Seat Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-18D-14 Cab Support Tool Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-19D-15 Engine Stand Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-20D-16 Engine Stand Bracket Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-21D-17 Engine Stand Bracket Rear Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-22D-18 Engine Stand Bracket Side Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-23D-19 Headlight Adjustment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-24D-20 Machine Gun Ring Drill Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-25D-21 Main Valve Body Spring Compression Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-26D-22 Spanner Socket Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-27D-23 Spanner Wrench Tool Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-28D-24 Spanner Wrench Jaw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-29D-25 Spanner Wrench Handle Piece . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-29D-26 Spreader Bar Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30D-27 Spreader Bar Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-31D-28 Steering Stop Shim Gage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32D-29 Transfer Case Lift Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-33D-30 Transfer Case Lift Bracket Main Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34D-31 Transfer Case Bracket Bolt Mounting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-35D-32 Transfer Case Lift Bracket Lifting Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-36D-33 Transfer Case Lift Bracket Center Support Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-37D-34 Transfer Case Lift Bracket Lifting Plate Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-38D-35 Transfer Case Lift Bracket Bolt Mounting Bracket Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-39D-36 Transmission Lift and Mounting Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-40D-37 Transmission Lift and Mounting Bracket Bottom Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-41D-38 Transmission Lift and Mounting Bracket Side Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-42D-39 Transmission Lift and Mounting Bracket Top Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-43D-40 Transmission Lift and Mounting Bracket Top and Bottom Braces . . . . . . . . . . . . . . . . . . . . . . . . . . . D-44D-41 Transmission Lift and Mounting Bracket Side Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-45D-42 Transmission Lift and Mounting Bracket Bolt Mounting Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-46D-43 Transmission Lift Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-47D-44 Lower Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48D-45 Upper Lift Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49D-46 Battery 12V Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-51D-47 Battery Ground Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-53D-48 Battery 24V Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-54D-49 Lanyard Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-60D-50 Wooden Skid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-61D-51 CTIS Seal Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-63D-52 Front Axle Shaft Seal Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-64D-53 Wheel Hub Grease Seal Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-65D-54 Differential Pinion Seal Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-66

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LIST OF ILLUSTRATIONS (CONT)

Figure Title Page

D-55 Front and Rear Differential Yoke Seal Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-67D-56 Purge Valve Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-69

LIST OF TABLES

Number Title Page

2-1 Vehicle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72-2 Engine System Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-132-3 Cooling System Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-652-4 Transmission System Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-732-4.1 C3 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5652-4.2 C3 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5792-4.3 C3 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-588.12-4.4 C3 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9432-4.5 C3 Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9572-5 Wheel Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9592-6 Hydraulic System Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9632-7 Steering Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9692-8 11K Self-Recovery Winch (SRW) Fault Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9753-1 Crankshaft Positions for Valve Clearance Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1013-2 Valve Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1033-3 Valve Clearance Ranges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1034-1 Crankshaft Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-207-1 Torque Converter Shim Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-147-2 Torque Converter End Play Shim Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16

20-1 Valve Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1220-2 Valve Spring Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1320-3 Valve Seat Insert Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1420-4 Cylinder Head Surface Flatness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-1520-5 Crankshaft Main Bearing Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3320-6 Crankshaft Connecting Rod Journal Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-3320-7 Piston/Piston Ring Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-4520-8 Camshaft Minimum Lobe Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-5421-1 Selective Spacer Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-1223-1 Pinion Bearing Preload Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1323-2 Pinion Cone Variation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-1624-1 Pinion Bearing Preload Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-1324-2 Pinion Cone Variation Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-16D-1 Pneumatic Tube Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-56D-2 Non-Metallic Electrical Cable Conduit Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-58E-1 Dry Torque Limits for SAE and ANSI Screws and Free Spinning Nuts . . . . . . . . . . . . . . . . . . . . . . . . E-2E-2 Dry Torque Limits for SAE and ANSI Prevailing Torque Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4E-3 Dry Torque Limits for Metric Screws and Free Spinning Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-5E-4 Dry Torque Limits for Metric Prevailing Torque Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6E-5 Wet Torque Limits for SAE and ANSI Screws and Free Spinning Nuts . . . . . . . . . . . . . . . . . . . . . . . . E-7

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HOW TO USE THIS MANUAL

OVERVIEW

This Technical Manual (TM) is provided to help you maintain the LMTV at the Direct Support (DS) and General Support(GS) Maintenance levels. This volume, Volume 1, contains Troubleshooting information which will assist you inmaintaining your LMTV. Volume 2 contains the DS and GS Maintenance procedures. Volume 1 contains the followingmajor sections in order of appearance:

• WARNING SUMMARY. Provides a summary of the most important warnings that apply throughout themanual. Read all WARNINGS and CAUTIONS before performing any troubleshooting or maintenanceprocedure.

• TABLE OF CONTENTS. Lists, for both volumes, the chapters, sections, appendixes, and indexes with pagenumbers in order of appearance.

• CHAPTER 1, INTRODUCTION. Describes the LMTV and provides equipment data.

• CHAPTER 2, VEHICLE MAINTENANCE. This chapter contains information for finding tools; special tools;Test, Measurement, and Diagnostic Equipment (TMDE); and repair parts. It also contains the troubleshootingtables.

• APPENDIX A, REFERENCES. Lists publications used with the LMTV and reference publications whichcontain information regarding the equipment.

• APPENDIX B, TOOLS AND SPECIAL TOOLS LIST. Lists equipment used in the performance ofmaintenance.

• APPENDIX C, EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST. Lists expendable and durableitems used in the performance of maintenance.

• APPENDIX D, ILLUSTRATED LIST OF MANUFACTURED ITEMS. Illustrates and describes items that mustbe fabricated from bulk materials for repair of the LMTV.

• APPENDIX E, TORQUE LIMITS. Lists the standard torque values for specific attaching hardware.

• APPENDIX F, MANDATORY REPLACEMENT PARTS.

• APPENDIX G, ADDITIONAL AUTHORIZATION LIST (AAL). Lists additional items you are authorized forthe support of the LMTV.

• APPENDIX H, TRANSMISSION/TRANSMISSION CONTROLS ADAPTABILITY CHART. Lists actionsrequired to mate different transmission configurations with WTEC II or WTEC III controls.

• SUBJECT INDEX. Lists important subjects contained in Volume 1 and Volume 2 in alphabetical order andgives the paragraph number where they are located.

Volume 2 contains the following major sections in order of appearance:

• WARNING SUMMARY. Provides a summary of the most important warnings that apply throughout themanual. Read all WARNINGS and CAUTIONS before performing any troubleshooting or maintenanceprocedure.

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OVERVIEW (CONT)

• TABLE OF CONTENTS. Lists the chapters, sections, appendixes, and indexes with page numbers in orderof appearance.

DIRECT SUPPORT MAINTENANCE

• MAINTENANCE PROCEDURES. DS and GS Maintenance procedures to assist you in supporting the LMTV.Chapters 3 through 19 are Direct Support Maintenance procedures. General Support Maintenanceprocedures are contained in chapters 20 through 24. Become familiar with the entire maintenance procedurebefore beginning any maintenance task.

• CHAPTER 3, ENGINE MAINTENANCE

• CHAPTER 4, FUEL SYSTEM MAINTENANCE

• CHAPTER 5, COOLING SYSTEM MAINTENANCE

• CHAPTER 6, ELECTRICAL SYSTEM MAINTENANCE

• CHAPTER 7, TRANSMISSION MAINTENANCE

• CHAPTER 8, POWER TRANSFER AND FINAL DRIVE ASSEMBLY MAINTENANCE

• CHAPTER 9, FRONT AXLE MAINTENANCE

• CHAPTER 10, REAR AXLE MAINTENANCE

• CHAPTER 11, BRAKE SYSTEM MAINTENANCE

• CHAPTER 12, STEERING SYSTEM MAINTENANCE

• CHAPTER 13, FRAME MAINTENANCE

• CHAPTER 14, SUSPENSION MAINTENANCE

• CHAPTER 15, BODY AND CAB MAINTENANCE

• CHAPTER 16, 11K SELF-RECOVERY WINCH (SRW) MAINTENANCE

• CHAPTER 17, HYDRAULIC SYSTEM MAINTENANCE

• CHAPTER 18, KIT MAINTENANCE

• CHAPTER 19, ARMAMENT/SIGHTING AND FIRE CONTROL MATERIEL MAINTENANCE

GENERAL SUPPORT MAINTENANCE

• CHAPTER 20, ENGINE MAINTENANCE

• CHAPTER 21, TRANSMISSION MAINTENANCE

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GENERAL SUPPORT MAINTENANCE (CONT)

• CHAPTER 22, POWER TRANSFER AND FINAL DRIVE ASSEMBLY MAINTENANCE

• CHAPTER 23, FRONT AXLE MAINTENANCE

• CHAPTER 24, REAR AXLE MAINTENANCE

• APPENDIX A, REFERENCES. Lists publications used with the LMTV and reference publications whichcontain information regarding the equipment.

• APPENDIX B, TOOLS AND SPECIAL TOOLS LIST. Lists equipment used in the performance ofmaintenance.

• APPENDIX C, EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST. Lists expendable and durableitems used in the performance of maintenance.

• APPENDIX D, ILLUSTRATED LIST OF MANUFACTURED ITEMS. Illustrates and describes items that mustbe fabricated from bulk materials for repair of the LMTV.

• APPENDIX E, TORQUE LIMITS. Lists the standard torque values for specific attaching hardware.

• APPENDIX F, MANDATORY REPLACEMENT PARTS.

• APPENDIX G, ADDITIONAL AUTHORIZATION LIST (AAL). Lists additional items you are authorized forthe support of the LMTV.

• APPENDIX H, TRANSMISSION/TRANSMISSION CONTROLS ADAPTABILITY CHART. Lists actionsrequired to mate different transmission configurations with WTEC II or WTEC III controls.

• SUBJECT INDEX. Lists important subjects contained in Volume 2 in alphabetical order and gives theparagraph number where they are located.

FINDING INFORMATION

There are several ways to find the information you need in this manual. They are as follows:

• FRONT COVER INDEX. The front cover index contains a list of the most important topics contained in eachvolume. It features a black box at the right edge of the cover which corresponds with a black box on thepage containing the topic. The topics listed on the front cover are highlighted in the table of contents witha box.

• TABLE OF CONTENTS. Lists chapters, sections, appendixes, and indexes with page numbers in order ofappearance.

• CHAPTER INDEXES. List paragraphs contained in the individual chapters with paragraph and page numbersin order of appearance.

• SYMPTOM INDEX. Lists malfunctions contained in the troubleshooting table with page numbers in order ofappearance.

• SUBJECT INDEX. Lists all maintenance procedures contained in Volume 2 in alphabetical order and givesthe paragraph number where they are located.

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TROUBLESHOOTING

Troubleshooting is contained in Chapter 2 of Volume 1. When a malfunction occurs, look at the symptom index for thevehicle troubleshooting table in Chapter 2. Find the malfunction in the index. Turn to the page number listed for themalfunction in the troubleshooting table. Perform the steps required to correct the malfunction. If you can’t find themalfunction, or the malfunction is not corrected, notify your supervisor.

FOLLOW THESE GUIDELINES WHEN USING THIS MANUAL:

• Become familiar with the entire maintenance procedure before beginning a maintenance task.

• Read all WARNINGS and CAUTIONS before performing any procedures.

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CHAPTER 1INTRODUCTION

PageSection I. GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1-1. SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11-2. MAINTENANCE FORMS, RECORDS, AND REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61-4. OFFICIAL NOMENCLATURE, NAMES AND DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61-5. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) . . . . . . . . . . . . . . . . . . . . . 1-61-6. WARRANTY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Section II. EQUIPMENT DESCRIPTION AND DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-61-7. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES . . . . . . . . . . . . . . . . . . . . . . . . 1-61-8. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-9. DIFFERENCES BETWEEN MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Section III. PRINCIPLES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-10. POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-71-11. ENGINE AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-91-12. FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-101-13. COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-121-14. ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-141-15. BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-201-16. STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-221-17. 11K SELF-RECOVERY WINCH (SRW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-231-18. AIR TRANSPORTABILITY HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-241-19. AIR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26

Section I. GENERAL INFORMATION

1-1. SCOPE

This chapter provides general information, equipment description, and principles of operation for the M1078 seriesLight Medium Tactical Vehicle (LMTV). The LMTV will herein be referred to as the vehicle.

a. Type of Manual: Direct Support Maintenance and General Support Maintenance Instructions, TM 9-2320-365-34-1.

b. Model Numbers and Equipment Names. The vehicle model numbers and names are listed below:

M1078 Truck, Cargo: 2 1/2-Ton, 4x4, Dropside (Figure 1-1).M1079 Truck, Van: 2 1/2-Ton, 4x4 (Figure 1-2).M1080 Truck, Chassis: 2 1/2-Ton, 4x4 (Figure 1-3).M1081 Truck, Cargo: 2 1/2-Ton, 4x4, Dropside, AIR DROP (Figure 1-4).

c. Purpose of Equipment. The LMTV series is a family of 4x4 wheeled vehicles. The purpose of these vehiclesis as follows:

(1) M1078 - Cargo hauling vehicle; can be outfitted for troop transport when equipped with a troopseat kit.(2) M1079 - Van; can be outfitted with commumications equipment or shop equipment.(3) M1080 - Vehicle chassis; this chassis will accept a cargo bed or may be modified for special missions.(4) M1081 - Cargo hauling vehicle; can be airdropped and outfitted for troop transport when equipped with a

troopseat kit.

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1-1. SCOPE (CONT)

LEFT FRONT VIEW

RIGHT REAR VIEW

Figure 1-1. M1078 Truck, Cargo: 2 1/2-Ton, 4x4, Dropside

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LEFT FRONT VIEW

RIGHT REAR VIEW

Figure 1-2. M1079 Truck, Van: 2 1/2 Ton, 4x4

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1-1. SCOPE (CONT)

LEFT FRONT VIEW

RIGHT REAR VIEW

Figure 1-3. M1080 Truck, Chassis: 2 1/2-Ton, 4x4

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LEFT FRONT VIEW

RIGHT REAR VIEW

Figure 1-4. M1081 Truck, Cargo: 2 1/2-Ton, 4x4, AIR DROP

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1-2. MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (asapplicable) DA Pam 738-750. The Army Maintenance Management Systems (TAMMS); DA Pam 738-751, FunctionalUsers Manual for the Army Maintenance Management Systems; or AR 700-138. Army Logistics Readiness andSustainability.

1-3. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

Command decision, according to the tactical situation, will determine when the destruction plan of the M1078 vehicleswill be accomplished. A destruction plan will be prepared by the using organization unless one has been prepared bya higher authority. For general destruction procedures for this equipment, refer to TM 750-224-6, Procedures forDestruction of Tank-Automotive Equipment to Prevent Enemy Use (U.S. Army Tank-automotive and ArmamentsCommand).

1-4. OFFICIAL NOMENCLATURE, NAMES AND DESIGNATIONS

Table 1-1 lists the nomenclature cross-reference used in this manual.

Table 1-1. Nomenclature Cross-Reference

Common Name Official Nomenclature

Cold Start System Ether Quick-Start SystemEngine Coolant Antifreeze, Ethylene, Glycol, InhibitedGladhand Quick-Disconnect CouplingVehicle Light Medium Tactical Vehicle (LMTV)

1-5. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

If your Light Medium Tactical Vehicle (LMTV) needs improvement, let us know. Send us an EIR. You, the user, arethe only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design. Putit on an SF 368 (Quality Deficiency Report). Mail it to us at: Commander, U.S. Army Tank-automotive and ArmamentsCommand, ATTN: AMSTA-TR-E/FMTV/312, Warren, MI 48397-5000. We’ll send you a reply.

1-6. WARRANTY INFORMATION

Refer to M1078 Series Warranty Program Technical Bulletin, TB 9-2300-365-15, for complete warranty informationcovering the vehicle. Warranty starts on the date found in block 23, DA Form 2408-9, in the logbook. Report alldefects in material or workmanship to your supervisor, who will take appropriate action.

Section II. EQUIPMENT DESCRIPTION AND DATA

1-7. EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

Refer to TM 9-2320-365-10 for equipment characteristics, capabilities, and features.

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1-8. LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

Refer to TM 9-2320-365-10 for location and description of major components.

1-9. DIFFERENCES BETWEEN MODELS

Refer to TM 9-2320-365-10 for differences between models.

Section III. PRINCIPLES OF OPERATION

1-10. POWERTRAIN

Figure 1-5. Powertrain

Power for the vehicle is provided by a diesel engine (1, Figure 1-5) which is coupled directly to an automatictransmission (2). Power from the automatic transmission is transferred to the transfer case (3) and on to the frontsteering and rear drive axles (4 and 5) through a series of drive shafts and universal joints. The vehicle drive train isenhanced by the use of an electronically controlled seven-speed transmission. The primary components of the AllisonMD3070PT transmission consist of a control module located directly beneath the transmission main housing; a ThrottlePosition Sensor (TPS) which detects the percentage of throttle being used; and engine, turbine, and output speedsensors which, in combination with each other, send information to the transmission ECU to provide the smoothestpossible shifting and allow the transmission ECU to monitor overall transmission performance. Transmission shiftcontrol is provided by one of two types of pushbutton shift selectors: The WTEC II Transmission ECU Pushbutton ShiftSelector (TEPSS) which contains an integral transmission ECU or the WTEC III Transmission Pushbutton Shift Selector(TPSS) which is coupled to an external transmission ECU.

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1-10. POWERTRAIN (CONT)

Figure 1-5. Powertrain (Cont)

a. Engine. The vehicle is equipped with a Caterpillar diesel engine, model 3116 ATAAC (Air-to Air After Cooler) (1,Figure 1-5), rated at 225 HP.

b. Transmission. The vehicle is equipped with an Allison automatic transmission, model MD3070PT (2, Figure 1-5).It is a fully automatic electronically controlled seven-speed close-ratio transmission.

(1) The TEPSS contains microprocessor based electronics, and is located in the instrument panel to the driver’s left.The TPSS is located in the instrument panel to the driver’s left, while the transmission ECU is located behind the kickpanel. The ECU receives information, in the form of electrical signals from the various sensors, processes thatinformation, then sends the appropriate signals to the solenoids which control transmission function. The ECUincorporates a diagnostic program which enables it to identify numerous actual and/or potential transmissionproblems. The TEPSS and TPSS are capable of displaying diagnostic codes in the Light Emitting Diode (LED)display on the pushbutton shift selector. These diagnostic codes are stored in the ECU for later retrieval. Thepushbutton shift selector is used for selecting transmission range. The transmission defaults to Neutral (N) wheneverelectrical power is removed from the vehicle. The Drive (D) gear selection is used for normal driving conditions. Thetransmission will engage 2nd gear when D is selected and the vehicle is stopped. As the accelerator is depressedand speed increases, the transmission will automatically upshift through 3rd, 4th, 5th, 6th, and 7th gears. Low gear(1st gear), is available only by manual selection. Selecting a specific gear; for example, 3rd; will prevent thetransmission upshifting past the selected gear. This is useful if road or load conditions require lower gear rangeoperation. When road conditions improve or load is reduced, the shift selector can be returned to the normal (D)driving position. When electrical power is applied to the TEPSS and a fault is detected in the transmission controls,the TEPSS will emit an eight second series of beeps. When electrical power is applied to the TPSS and a fault isdetected in the transmission controls, "--" will appear in the TPSS LED display. In either case, the transmission willnot engage a range (forward or reverse) when D or Reverse (R) range is selected on the pushbutton shift selector.TM 9-2320-365-10 provides full operating instructions for the transmission.

(2) The transmission may include a Power Take-Off (PTO). The PTO powers a hydraulic pump which supplieshydraulic pressure for an 11K self-recovery winch (SRW).

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c. Transfer Case. The transfer case (3, Figure 1-5) provides the transmission (2) with the seventh gear (low gear,or 1st gear) and delivers power from the transmission to the front and rear driveshafts. In normal driving conditions,the transfer case splits the output torque of the transmission, providing 70 percent of the torque to the rear output driveyoke and 30 percent to the front output drive yoke. In low gear the output torque of the transmission is split evenly,with 50 percent going to the front output yoke and 50 percent going to the rear.

d. Suspension. The suspension system is designed to maintain tire/ground contact in all types of terrain. the vehicleis equipped with 395/85R20 tires. The tires have a tread pattern designed to maximize traction on all types of terrain.

e. Axles. Front and rear axles (4 and 5, Figure 1-5) feature wheel end planetary drives designed to allow the vehicleto carry heavy loads. When the vehicle is operated in MODE, all axles become driving axles. When the vehicle isoperated in MODE, 7th gear is unavailable.

1-11. ENGINE AIR INTAKE SYSTEM

Figure 1-6. Engine Air Intake System

The engine air intake system consists of a dry-type air cleaner (1, Figure 1-6), turbocharger (2), and a charge air cooler(3). The turbocharger increases engine horsepower by delivering a higher volume of air to the engine. Engine exhaustgases flow through the turbocharger, causing a turbine wheel to spin. As the turbine wheel spins, a compressor wheelon the opposite end of the turbine wheel shaft spins and draws fresh air through the air cleaner. The compressor wheelcompresses the air and delivers it to the charge air cooler. The air flows through the charge air cooler which cools theair before it is delivered to the engine cylinders. The charge air cooler allows a denser charge of air to be deliveredto the engine, which also aids in increasing engine horsepower.

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1-12. FUEL SYSTEM

Figure 1-7. Fuel System

The primary components of the fuel system are the fuel tank (1, Figure 1-7), fuel priming pump and fuel/water separator(2), fuel shutoff solenoid (3), engine fuel governor (4), and secondary fuel filter (5). The mechanical fuel pump actsas an engine priming feature. The fuel/water separator removes water and large solid particles from the fuel beforeit is passed to the engine fuel governor. The fuel shutoff solenoid, when energized, frees the governor output shaftto move to the FUEL ON position. When electrical power is removed from the fuel shutoff solenoid, the governor outputshaft is locked in the FUEL OFF position. The engine fuel governor contains a mechanical link to the fuel controllinkage and fuel transfer pump. The engine fuel governor responds to input from the accelerator pedal and causes thefuel control rack to rotate, resulting in an increase or decrease in engine speed. The governor adjusts the amount offuel delivered to the engine as engine speed changes. The secondary fuel filter removes finer particles from the fuelbefore it reaches the cylinder head. A fuel pressure regulator redirects excess fuel, through a fuel return hose, backto the fuel tank.

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Figure 1-7. Fuel System (Cont)

Additionally, the vehicle is equipped with an ether quick start system designed for starting the engine when ambienttemperatures are below 32°F (0°C). The ether quick start system is composed of an ether cylinder (6), ether valve (7),two ether nozzles (8), and an ether sensor switch (9). The ether sensor switch detects the temperature of the enginecoolant and disables the ether valve above 32°F (0°C). The ether valve delivers a controlled charge of ether to theether nozzles.

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1-13. COOLING SYSTEM

Figure 1-8. Cooling System

a. Cooling System. The pressurized cooling system protects the engine, transmission, and air compressor byproviding a means of dissipating heat generated during operation of the vehicle. The radiator pressure cap (1, Figure1-8), in combination with the ethylene glycol-based antifreeze, effectively raises the boiling point of the coolant to wellabove 212°F (100°C). The thermostat (2), located in a housing on the right side of the engine, helps the engine towarm up quickly by remaining closed until the coolant temperature reaches approximately 180°F (82°C). When thecoolant reaches 199°F (93°C), the thermostat is fully open and coolant is circulated through the water jackets in theengine to maintain the correct operating temperature for the engine. Coolant is drawn from the radiator (3), throughthe transmission oil cooler (4), and circulated throughout the cooling system by the water pump (5). The water pump,located on the front of the engine toward the right side, is driven by two V-belts from the crankshaft pulley.

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Figure 1-8. Cooling System (Cont)

An engine fan (6) with pneumatic clutch is activated by the water temperature switch (7). When this switch detects ahigh temperature condition, air pressure is removed from the fan clutch and the engine fan is engaged. Excess heatis drawn from the radiator by the flow of air created by the engine fan over the radiator cooling fins. A radiator overflowtank (8) is provided to allow for expansion of the coolant. The radiator overflow tank also serves as the point wherenew coolant is introduced into the cooling system.

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1-14. ELECTRICAL SYSTEM

Figure 1-9. Electrical System

In the Electrical System, a heavy duty starting motor (1, Figure 1-9) is mounted on the engine flywheel housing andprovides the cranking power necessary for starting the engine. The voltage regulator (2) maintains both a 14- and 28-volts level for proper battery charging. The alternator (3) provides sufficient amperage to operate all electricalcomponents and charge the batteries during engine idling. Vehicle exterior lights are mounted in protective locationsor are protected to prevent damage. Protection is provided for lights during cross country travel. Polycarbonate lensesare provided for all lights except the sealed beam headlights. The electrical system supplies all of the electrical powerneeded to operate the vehicle and trailer. The complete Electrical System is made up of the following subsystems:

• Power Storage and Generating • Accessory Lighting• Engine Starting and Stopping • Instruments• Service Lighting • Indicator Lights and Alarm• Blackout Lighting • Troubleshooting Aid

a. Power Storage and Generating. Power storage for the vehicle consists of four 12-volt batteries. The four batteriesare divided into two sets. Two batteries in each set are wired in parallel to produce higher amperage. The two setsare then wired in series to produce 24 volts Direct Current (DC). While the batteries can power all of the systems fora limited time, their primary purpose is to supply power to the engine starting system. Once the engine is running, thegenerating system provides electrical power for all of the systems. The engine driven alternator generates AlternatingCurrent (AC) which is passed through a set of rectifiers that change it into DC current. This DC current is used tocharge the batteries and is distributed to the electrical sub-systems of the vehicle. The voltage regulator adjustsalternator output to fit the needs of the electrical system.

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ARMY TM 9-2320-365-34-1 AIR FORCE T.O. 36A12-1B-1095-12-1ARMY TM 9-2320-365-34-1 AIR FORCE T.O. 36A12-1B-1095-12-1 TECHNICAL MANUAL HEADQUARTERS NO. 9-2320-365-34-1 DEPARTMENTS OF

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